Polymer coated fertilizer

ABSTRACT

A controlled release fertilizer has been prepared comprising a nutrient core coated with one or more moisture barrier coatings, at least one of said moisture barrier coatings comprising: at least one polyethylene wax; and a thermoset polyurethane from the reaction of a polyol and a polyisocyanate. The weight ratio of thermoset polyurethane to polyethylene wax is from about 50:50 to about 98:2. The polyethylene wax is heated above the melt point of the polyethylene wax and mixed and dispersed into the polyol component of the thermoset polyurethane in a ratio of 90-70% polyol to 10-30% polyethylene wax before the thermoset polyurethane-forming mixture is applied to the surface of the nutrient core and cured. A coating of a high temperature microcrystalline wax can be applied prior to final curing of the thermoset polyurethane to the coated nutrient core particles.

FIELD OF THE INVENTION

This invention relates to the art of fertilizer and, more particularly,to a coated granular fertilizer in which the dissolution rates ofwater-soluble fertilizer components are controlled by coating orencapsulating a granular fertilizer.

BACKGROUND OF THE INVENTION

Achieving crop fertilization by timing the release or application offertilizer nutrients is known. Fertilization in the container-grownwholesale plant industry, for example, has been accomplished by methodsincluding:

Multiple applications of granular fertilizer

Overhead liquid application of soluble fertilizers

Incorporating slow release fertilizers into potting soil

Polymer coated fertilizers.

Existing controlled release fertilizers have limited use in specialtyagricultural markets where tropical (hot/humid/wet) conditions exist.Prior controlled release fertilizers are either not cost effective foruse in these markets or do not perform as claimed (lacking true productlongevity) or desired by the grower.

A new product is needed because existing, cost-effective, polymer coatedfertilizers for use in specialty agricultural do not perform as demandedin tropical conditions. Excess heat (over 90° F.) can stress the coatingof other fertilizer and accelerate their release and dramatically reducetheir overall effectiveness in the field.

Inefficient fertilization using past existing polymer coated fertilizersincreases costs and losses with respect to crops. To achieve the saferelease of nutrient, current coated fertilizers must be relativelythickly coated, as measured by percentages of weight. Thicker coatingsare necessarily costlier as result of, inter alia, the need for morecoating materials. What is needed is an encapsulated fertilizer that cansafely release nutrient to plants using coating that is more efficient.

SUMMARY OF THE INVENTION

The present invention to a process for producing polyurethaneencapsulated, fertilizer substrate (particles). The process comprisesapplying an isocyanatereactive component that includes a polyolcontaining a polyethylene wax (curable sealant) to form a coating on thefertilizer particles and applying an isocyanate component onto saidfertilizer particles and curing the coating and further comprisingapplying a high temperature point microcrystalline wax to the coatedparticles during the last stages of curing of the isocyanate-containingcoating. The applications of each component may be repeated to form thepolyurethane encapsulated fertilizer particles. The particle coating canpreferably have a minimum of 2% coating by weight with a minimum of 2two polyurethane layers, or a maximum coating weight of 5% or 4 fourpolyurethane layers.

Among the features of the invention is that the coating compositioncomprises a curable sealant wherein a wax sealant is built into thepolymer membrane/matrix thus eliminating an added step requiring aseparate additive sealant layer. A second feature of the invention isthe application of a high temperature microcrystalline wax to theparticles during the final stages of the curing of the polyurethanelayer.

The present invention encompasses a novel continuous process productionmethod for coating instead of the current batch production method.

One of the advantages of the present invention is that the presentcoated fertilizer can have 45% or more Nitrogen for controlled releasefertilizer. Currently a 44.5% is the maximum available commerciallyavailable product. Optionally, the present invention can comprise theaddition of dry powdered ingredients/nutrients such as, for examplebio-stimulants underneath the coating.

The present invention utilizes a second wax coating comprising a highheat (micro-crystalline) wax application during the final stages of thecuring of the polyurethane to cure on the hot material being cured thusavoiding final cooling step in the process; basically, heating liquidwax to about 190° F. and spraying onto about 160° F. product and curinginstantly. A non-limiting example of a high temperature microcrystallinewax useful in the present invention is MICROSERE@ 5890A. MICROSERE@5890A is a white, high-melt, microcrystalline wax that is used in avariety of applications. MICROSERE@ 5890A complies with the requirementsfor “Microcrystalline Wax” set by the United States Pharmacopeia(USP)/National Formulary (NF). MICROSERE@ 5890A has the followingproperties:

PHYSICAL PROPERTIES TEST ASTM SPECIFICATIONS METHODS METHOD MinimumMaximum TYPICAL Drop Melt Point D 127 175 79.4 188 86.7  181 (82.8 ° F.° C. Kinematic D 445 14.0 Viscosity, cSt 212° F. 100° C. Oil Content, D721 2.0 Wt. % Sa bolt Color D 6045 +16 Odor D 1833 2 1 Needle Penetra- D1321 15 22 21 tion, dmm 77° F. 250 C. Note: Physical properties forwhich ONLY a typical value is listed are included as additionalinformation but may not be printed on the COA.FDA Status:

This product meets the FDA requirements set forth in 21 CFR 178.3710 foruse in nonfood articles in contact with food. For additional FDAcompliance information, please contact your IGI Sales Representative.

An advantage of the present invention is that the invention can befocused on specialty agricultural markets and on improving crop yields.

The present invention provides a technology which allows for a coatingthat is thinner than presently available products on the market whereinthe new coated fertilizer increases the Nitrogen value and provides amore cost-effective cost per unit of Nitrogen. for the grower whenapplying fertilizer. The grower is therefore able to use fewer totaltons (less cost and environmental burden) to achieve a similar desiredresult/yield. The novel coated fertilizer provides a more efficientdelivery of nutrients to the crop in that it releases nutrients morelineal or time in tropical conditions compared to competitive products.

The present invention solves the problem of providing agriculturalgrower in tropical conditions (such as, for example Florida) with a costeffective and enhanced efficiency form of fertilizer when compared toconventional ‘raw’ or uncoated granular fertilizer or other polymercoated fertilizers currently on the market.

The present invention also reduces environmental nitrogen/nutrient lossfrom volatilization or leaching into ground water and can save growerscost with a more efficient product that allows them to apply lessoverall material to their crops.

DETAILED DESCRIPTION OF THE INVENTION

The present comprises controlled release fertilizer comprising anutrient core coated with one or more moisture barrier coatings, atleast one of said moisture barrier coatings comprising: at least onepolyethylene wax; and a thermoset polyurethane from the reaction of apolyol and a polyisocyanate. The weight ratio of thermoset polyurethaneto polyethylene wax is from about 50:50 to about 98:2, and thepolyethylene wax is heated above the melt point of the polyethylene waxand mixed and dispersed into the polyol component of the thermosetpolyurethane in a ratio of 90-70% polyol to 10-30% polyethylene waxbefore the thermoset polyurethane-forming mixture is applied to thesurface of the nutrient core and cured. A coating of a high temperaturemicrocrystalline wax which is applied prior to final curing of thethermoset polyurethane to the coated nutrient core particles.

MDI can be the curing agent for the preparation of the thermosetpolyurethane and the particle coating preferably has a minimum of 2%coating by weight with a minimum of 2 polyurethane layers, or a maximumcoating weight of 8% or 4 polyurethane layers.

A bio-stimulant is optionally applied to the nutrient core prior tocoating or added to the microcrystalline wax

The method of producing a controlled release fertilizer of the presentinvention comprises the steps of: providing a quantity of nutrient coreparticles; heating the nutrient core particles to a temperature abovethe melting point of a polyethylene wax polyol mixture; providing one ormore moisture barrier coatings, at least one of said moisture barriercoatings comprising: at least one polyethylene wax; and a thermosetpolyurethane from the reaction of a polyol and a polyisocyanate; heatingthe polyol component of the polyurethane to a temperature above themelting point of the polyethylene wax; dispersing the polyethylene waxinto the heated polyol and forming a dispersion of polyethylene wax inthe heated polyol; applying the dispersion of polyethylene wax andpolyol and polyisocyanate to the nutrient core particles while providingmixing enough to spread the dispersion as a coating on the fertilizerparticles; curing the thermoset polyurethane on the surface of theparticles to form free flowing coated granules; and in the final stagesof the curing of the polyurethane coating applying to the coatedfertilizer particles with a high temperature microcrystalline wax andcontinued curing the coated fertilizer particles and cooling the coatednutrient particles to form polyurethane coated particles having an outerlayer of solidified microcrystalline wax. The weight ratio of thermosetpolyurethane to polyethylene wax is from about 50:50 to about 98.2.heating the polyol component of the polyurethane to a temperature abovethe melting point of the polyethylene wax;

A bio-stimulant is optionally applied to the nutrient core particles oradded to the microcrystalline wax.

The coated granular fertilizer according to the invention comprises aparticulate fertilizer which is coated with a novel resin composition.The particulate fertilizer used in the present invention is not criticalwith respect to the type and may be any known chemical fertilizer.Examples of the fertilizer include ammonium sulfate, ammonium chloride,ammonium nitrate, urea, potassium chloride, potassium sulfate, potassiumnitrate, sodium nitrate, ammonium phosphate, potassium phosphate,calcium phosphate, and composite fertilizers thereof.

The granular fertilizer is coated with a water-resistant film-formingpolyurethane composition. The composition should comprise anisocyanate-reactive polyol and an isocyanate component, and a second waxcoating of a high heat (micro-crystalline) wax prior to final curing.

The isocyanate can be, for example a diisocyanate, or a polyisocyanate.A nonlimiting example of a diisocyanate is polymeric MDI (4,4diphenylmethane diisocyanate), however, other poly-functionalisocyanates can be utilized and include aliphatic, aromatic, andaliphatic aromatic polyisocyanates. Isocyanates containing two or moreNCO groups available for reaction and, as known to one skilled in theart, are widely used in the production of urethane polymers.Non-limiting examples of suitable isocyanates include: 1,6-hexamethylenediisocyanate, 1,4-butylene diisocyanate, furfuryurylidene diisocyanate,2,4-toluene diisocyanate, 2,6 toluene diisocyanate, 2,4′diphenylmethanediisocyanate, 4,4′-diphenylmethane diisocyanate, 4,4′diphenylpropanediisocyanate, 4,4′-diphenyl-3,3′-dimethyl methane diisocyanate,1,5naphthalene diisocyanate, 1-methyl-2,4-diisocyanate-5-chlorobenzene,2,4diisocyanato-s-triazine, 1-methyl-2,4-diisocyanato cyclohexane,p-phenylene diisocyanate, m-phenylene diisocyanate, 1,4-naphthalenediisocyanate, dianisidine diisocyanate, bitoluene diisocyanate,1,4-xylylene diisocyanate, 1,3-ylylene diisocyanate,bis-(4-isocyanatophenyl)methane,bis-(3-methyl-4-isocyanatophenyl)methane, polymethylene polyphenylpolyisocyanates and mixtures thereof. MDI (4,4 diphenylmethanediisocyanate) is a preferred isocyanate.

The present coated fertilizer can have a coating of up to about 2%.

The organic wax can be at least one selected from the group consistingof petroleum waxes, synthetic waxes, waxes, natural waxes, andhydrogenated triglycerides. The organic wax can be a paraffin. Thepolyethylene wax useful in the present invention is a waxy solid havinga melting point range of between 55° and 85° C. preferably between 60°and 70° C. The polyethylene wax is a LDPE. The polyethylene was maycontain a wax soluble polymer.

A wax soluble polymer can be added to the polyethylene wax which issubstantially non-reactive with the said thermoset polymer. The waxsoluble polymer can form a homogeneous mixture with the said wax at 100°C. The wax soluble polymer can have a viscosity of less than 10.000centipoise at 100° C. when at least 2 percent by weight is mixed withthe said wax. The wax soluble polymer can be at least one selected fromthe group consisting of ethylene-vinyl acetate copolymers andterpolymers, modified polyolefins, acrylate ester polymers andcopolymers, and tackifying resins

The thermoset polymer is a polyurethane.

The coating process of the present invention can be carried out in thefollowing manner.

Fertilizer Substrate (particles) is screened to remove any fines (dust)or off sized material. It is preferred in the present invention to endup with a fertilizer product that has an SGN (Size Guide Number) of 280.A 220-250 SGN product is typically used for turf.

A preferred embodiment of the present invention is to have a largerparticle for the product line as this will be going into theagricultural markets and will create a more uniform blend when mixedwith other fertilizer components. The larger product size also requiresless coating by weight to achieve the optimum performance. The 280 SGNfertilizer granule has less surface area compared to the 220-250 SGN.When adding the same amount of coating to each product, the 280 SGNproduct will have a slightly thicker coating on each granule thus makingit last slightly longer with the same amount of coating.

The fertilizer substrate is heated by, for example running the substratethrough a fluidized preheater. This serves two purposes. First, itremoves any additional dust that is left on the substrate, secondly, itbrings the temperature of the substrate up to about 160-165° F. to startthe coating process. 160-165° F. is the preferred temperature whichdelivers a high-quality finished product.

The fertilizer substrate is placed into a coating vessel where alayering process is begun. It is noted that the coating may be carriedout in one or more stages. Inside the coating vessel drum, theIsocyanate (ISO) is applied first and the curable sealant (CS) of thepresent invention second at a preferred 54%/46% ratio. This combinationcreates a “layer”. In a multiple application procedure, each layer isgiven about 5 minutes to cure before the next layering process isstarted. The preferred product of the present invention can have as fewas 2 layers and as many as 4.

After the last layer of ISO/CS is added and is in the later stage ofcuring, a highmelt microcrystalline wax is added to the product. Thehigh-melt wax starts as a solid. The wax is heated to a temperature ofabout 200° F. in a melting tank at which points it becomes a liquid. Thehigh-melt microcrystalline wax is then sprayed on to later stage ofcuring of the polyurethane coated fertilizer substrate. The wax becomessolid again and “set” at about 181° F. Since the fertilizer bed is about160-165° F., the wax will rapidly encapsulate the coated fertilizersubstrate and harden. Using the high-melt microcrystalline wax allowsthe product to be released from the coating vessel and put directly intobulk storage bins without going through an additional cooling step thatother CRF technologies must go through when being manufactured.

An example of the present invention is as follows:

StdBOMqty Blank 44-0-0-045BT-YLD 44.5-0-0-BT-YLD 45-0-0-BT-YLD Chk BOMTotal Qty — 1.00000 1.00000 1.00000 Layer Type GA % 44.091 44.551 45.011Add'l/Dual Substrate — — — Primary Substrate 0.95850 0.96850 0.97850Total Coating Weight % 0.04150 0.03150 0.02150 ISO — — — Wax — — —Layer1 Iso 0.00540 0.00540 0.00540 Layer1 Curable Sealant 0.004600.00460 0.00460 WAX WAX — — — Layer2 Iso 0.00540 0.00540 0.00540 Layer2Curable Sealant 0.00460 0.00460 0.00460 WAX WAX — Layer3 Iso 0.005400.00540 — Layer3 Curable Sealant 0.00460 0.00460 — WAX WAX — Layer4 Iso0.00540 — Layer4 Curable Sealant 0.00460 — WAX WAX 0.00150 0.001500.00150

An optional step in the present invention process is the optionaladdition of a bio stimulant. During the addition of the high-meltmicrocrystalline wax, a bio stimulant may also be added to the coatedfertilizer substrate. This bio stimulant can be added and mixedthoroughly into the wax melting tank. By applying the bio stimulant withthe wax simultaneously, it can be ensured that each coated particle iscarrying the bio stimulant.

The forgoing detailed description is merely exemplary in nature and isnot intended to limit the invention or the application and uses of theinvention. As used herein, the word “exemplary” means “serving as anexample, instance, or illustration.” Thus, any embodiment describedherein as “exemplary” is not necessarily to be construed as preferred oradvantageous over other embodiments. All the embodiments describedherein are exemplary embodiments provided to enable persons skilled inthe art to make or use the invention and not to limit the scope of theinvention which is defined by the claims. Furthermore, there is nointention to be bound by any expressed or implied theory presented inthe preceding technical field, background, brief summary, or thefollowing detailed description.

We claim:
 1. A controlled release fertilizer comprising a nutrient corecoated with one or more moisture barrier coatings, at least one of saidmoisture barrier coatings-consisting essentially of: at least onepolyethylene wax; and a thermoset polyurethane from the reaction of apolyol and a polyisocyanate; wherein the weight ratio of the thermosetpolyurethane to polyethylene wax is from about 50:50 to about 98:2, andwherein the polyethylene wax is heated above the melt point of thepolyethylene wax and mixed and dispersed into the polyol component ofthe thermoset polyurethane in a ratio of 90-70% polyol to 10-30%polyethylene wax before the thermoset polyurethane-forming mixture isapplied to the surface of the nutrient core and cured, and wherein afterthe last layer of the polyurethane-forming coating is added onto thesurface of the nutrient core particles and is in the later stage ofcuring, a melted high-melt microcrystalline wax in liquid form issprayed onto the coated nutrient core particles and the high-meltmicrocrystalline wax solidifies and hardens upon contact with the coatednutrient particles and rapidly encapsulates the coated fertilizersubstrate to form the polyurethane coated particles having an outerlayer of solidified microcrystalline wax.
 2. The controlled releasefertilizer of claim 1, wherein MDI is the curing agent for thepreparation of the thermoset polyurethane.
 3. The controlled releasefertilizer of claim 1, wherein the particle coating has a minimum of 2%coating by weight with a minimum of 2 polyurethane layers, or a maximumcoating weight of 8% or 4 polyurethane layers.
 4. The controlled releasefertilizer of claim 1, wherein a bio stimulant is optionally applied tothe nutrient core prior to coating or added to the microcrystalline wax.5. A method of producing a controlled release fertilizer comprising thesteps of: providing a quantity of nutrient core particles; heating thenutrient core particles to a temperature above the melting point of apolyethylene wax polyol mixture; providing one or more moisture barriercoatings, at least one of said moisture barrier coatings consistingessentially of: at least one polyethylene wax; and a thermosetpolyurethane from the reaction of a polyol and a polyisocyanate; whereinthe weight ratio of thermoset polyurethane to polyethylene wax is fromabout 50:50 to about 98.2; heating the polyol component of thepolyurethane to a temperature above the melting point of thepolyethylene wax; dispersing the polyethylene wax into the heated polyoland forming a dispersion of polyethylene wax in the heated polyolwherein the dispersion comprises 90-70% polyol to 10-30% polyethylenewax; applying the dispersion of polyethylene wax and polyol andpolyisocyanate to the nutrient core particles while providing mixingenough to spread the dispersion as a coating on the fertilizerparticles, curing the thermoset polyurethane on the surface of theparticles to form free flowing coated granules; and wherein in the finalstages of the curing of the polyurethane coating after the last layer ofpolyurethane-forming coating is added onto the surface of the nutrientcore particles and is in the later stage of curing, a melted high-meltmicrocrystalline wax in liquid form is sprayed onto to the coatednutrient core particles and the high-melt microcrystalline waxsolidifies and hardens upon contact with the coated nutrient particlesand rapidly encapsulates the coated fertilizer substrate and cools thecoated nutrient particles to form polyurethane coated particles havingan outer layer of solidified microcrystalline wax.
 6. The method ofclaim 5, wherein a bio stimulant is optionally applied to the nutrientcore particles or added to the microcrystalline wax.